Evaporative cooling system installed in a structure wall

ABSTRACT

An evaporative cooling system includes a housing that fits between a pair of wall studs of a structure. The housing includes a water pump, an evaporative pad, a water distributor, a motor, and a fan. In an embodiment, the wall studs are spaced about sixteen inches on center. This leaves about 14.5 inches between the studs, and the housing will preferably be about 14 inches in width to ensure proper fit. The unit may be about 3 to 6 inches in thickness and about 24 inches in height, protruding no more than about three inches from the inside wall. The housing also preferably includes a front cover. A ventilation grill can be installed on the exterior wall to facilitate outside air being brought into the system. In other embodiments, the studs are spaced differently (e.g., about twenty-four inches on center) or the unit is installed in a structure built using non-wood framing (e.g., SIP, ICF).

FIELD OF THE INVENTION

The present invention relates to the field of evaporative coolers, and, more particularly, to an evaporative cooling system installed in a structure wall.

BACKGROUND

Evaporative coolers are well known in the prior art. For example, U.S. Pat. No. 838,602 to Zellweger, issued in 1906, discloses an evaporative cooling system that used wood chips for the evaporative media and reportedly cooled the air by as much as 20 degrees. By the middle part of the 20^(th) Century typical designs for evaporative coolers included a water reservoir, a pump to circulate water over evaporative pads, and an electric blower to draw outside air through the pads, cooling the air by evaporation.

Today, many different types of evaporative coolers exist. Some evaporative coolers are mounted outside a dwelling and are used to cool the entire interior of the structure. Other evaporative coolers are used to cool smaller areas such as individual rooms. Window-mounted units are available but are bulky and protrude from the exterior of the structure which makes them unattractive and unacceptable to many homeowner associations. Also, such window units require an available window. Portable evaporative coolers include a set of wheels which allow them to be brought into a room to be cooled. However, such portable evaporative coolers can take up needed space, and require the user to periodically re-fill the tank with water. Moreover, portable evaporative coolers do not bring in fresh outside air. Instead, they continually recirculate interior air which decreases comfort and inhibits the ability to cool.

SUMMARY OF THE INVENTION

According to a preferred embodiment of the present invention, an evaporative cooling system includes a housing that fits between a pair of wall studs of a structure. The housing includes a water pump, an evaporative pad, a water distributor, a motor, and a fan. In an embodiment, the wall studs are spaced about sixteen inches on center. This leaves about 14.5 inches between the studs, and the housing will preferably be about 14 inches in width to ensure proper fit. The unit may be about 3 to 6 inches in thickness and about 24 inches in height, protruding no more than about three inches from the inside wall. The housing also preferably includes a front cover. A ventilation grill can be installed on the exterior wall to facilitate outside air being brought into the system. In other embodiments, the studs are spaced differently (e.g., about twenty-four inches on center) and the dimensions may vary to accommodate the spacing. In still other embodiments, the evaporative cooling system of the present invention is installed in walls constructed using other construction methods, such as structural insulated panels (SIP), insulating concrete form (ICF), etc.

In operation, the water pump brings water from the water reservoir to the water distributor and the water distributor distributes the water to the evaporative pad thereby moistening the pad. The fan causes an air path whereby relatively warmer outside air flows through the pad moistened by the water, thereby cooling the air by evaporation. The cooled air then flows through an opening in the front cover. Air can enter the evaporative cooling system from a vent in the back of the cooler open to the outside. At least some of the water will flow back to the water reservoir for recirculation. The cooling system further includes a ball float valve that opens to fill the water reservoir with the additional water when the water in the reservoir falls below a predetermined level. The cooling system further includes an overflow drain which regulates the quantity of water in the water reservoir and allows excess water to be channeled directly to the drain which relieves outside of the structure.

These and other aspects, features, and advantages of the present invention will become apparent from the following detailed description of preferred embodiments, which is to be read in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of an evaporative cooling system installed in a structure wall, according to a preferred embodiment of the present invention;

FIG. 2 shows another view of the evaporative cooling system;

FIG. 3 shows a view of the evaporative cooling system with the front cover removed;

FIG. 4 shows a side view of the evaporative cooling system; and

FIG. 5 shows an exterior view of the structure with a ventilation grill installed.

DETAILED DESCRIPTION

FIG. 1 illustrates a perspective view of an evaporative cooling system 100 installed in a structure wall 140, according to a preferred embodiment of the present invention. As shown, the evaporative cooling system 100 includes a front cover 130 which provides access to user controls 106. When the evaporative cooling system 100 is operated, cool air is blown from the evaporative cooling system 100 through an air opening 135 in the front cover 130 to the interior of the room. The present evaporative cooling system 100 is particularly well suited for cooling a garage but may be used in other structures as well.

FIG. 2 shows another view of the evaporative cooling system 100. As shown, the evaporative cooling system 100 is supplied with water from water supply 180, and includes an overflow drain 190 which allows excess water to be channeled directly to the drain which relieves outside of the structure. Electric power is supplied by electric wiring 170 which preferably will be standard 120 V AC current.

FIG. 3 shows a view of the evaporative cooling system 100 with the front cover 130 removed for illustrative purposes. As shown, the evaporative cooling system 100 includes a housing 160 that includes therein the following components: an electric motor 102, a fan 104, the user controls 106 (including an on/off switch 107 and a speed-selection switch 108), a water reservoir 110, a ball float valve 112, a water pump 114, a water distributor 118, an evaporative pad 115, and an overflow drain system 195. As shown, the housing 160 of the evaporative cooling system 100 is disposed between a pair of wall studs 150. In an embodiment, the wall studs 150 are spaced about sixteen inches on center. This leaves about 14.5 inches between the wall studs 150, and the housing 160 will preferably be about 14 inches in width to ensure proper fit. The 14 inches allows for there to be approximately 0.25 inches on each side of the housing 160 between the wall studs 150 in case they are not exactly centered or if there is a bow in the wall stud 150. In this embodiment, the housing 160 may be about 4 to 6 inches in thickness and about 24 inches in height, protruding no more than about three inches from the inside wall. In other embodiments, the wall studs 150 will be spaced differently and/or the thickness of the wall studs 150 will be different (e.g., 2×6 inch studs). In one embodiment the wall studs 150 will be spaced 24 inches on center leaving a space of 22.5 inches to accommodate the housing 160, so that the housing 160 can be made wider in this case. In 2×6 construction, the wall studs 150 would be 5.5 inches deep and the drywall would be ½ inch, so the housing 160 would not protrude from the structure wall 140 as much (or at all) as in the case of 2×4 inch wall studs 150.

It is to be appreciated that although discussion has been limited to traditional wood framing techniques, the evaporative cooling system 100 of the present invention can also be installed in walls constructed using other construction methods, such as structural insulated panels (SIP), insulating concrete form (ICF), etc. As far as SIP construction, a hole could be cut into the paneling and the foam insulation removed to accommodate the evaporative cooling system 100, and then the exterior could be cut just like in a traditional framing situation. In this case, there would be no studs; the unit would be anchored to the exterior of the SIP panels which are usually plywood. With ICF, before the concrete is poured into the walls, a piece of the concrete form could be cut out and a blank put in its place to accommodate the evaporative cooling system 100. After the concrete pour, the blank would be removed. An anchor could be disposed in the concrete, or the unit could alternatively be mounted using a wall fastening system or a wood frame, for example.

In operation, the water pump 114 brings water from the water reservoir 110 to the water distributor 118, and the water distributor 118 distributes the water to the evaporative pad 115 thereby moistening it. The fan 104, which is oriented to blow air into the room, creates an air path (as illustrated in FIG. 4) whereby relatively warmer/dryer outside air flows into a ventilation grill 190 (shown from the exterior in FIG. 5), and is channeled to the evaporative pad 115, thereby cooling the air by evaporation. The cooled air then flows through an opening 135 in the front cover 130. At least some of the water from the evaporative pad 115 will fall back to the water reservoir 110 for recirculation. The evaporative cooling system 100 includes the ball float valve 112 that opens to fill the water reservoir 110 with the additional water when the water in the reservoir 110 falls below a predetermined level. The overflow drain system 195 regulates the quantity of water in the water reservoir 110 and allows excess water to be channeled directly to the drain which relieves outside of the structure.

As mentioned, the exact dimensions of the evaporative cooling system 100 will vary depending on the spacing of the wall studs 150, but can also vary depending on the needs of the user. For instance, it was found that using a FASCO Transflo Blower (a “squirrel cage” fan) rated at 115 cubic feet per minute (cfm) was adequate for cooling a typical garage; however, a more powerful fan could be used to accommodate a larger cooling area. Furthermore, the evaporative pad 115 could be increased in size (which might also involve increasing the height and/or width of the housing 106). The water pump 114 can be a submersible pump rated at about 190 gallons per minute (gpm), for example. The water distributor 118 can be constructed from a piece of one-half inch PVC pipe with holes drilled therein to allow the water to drip on to the evaporative pad 115, for example. The overflow drain system 195 can be a standard overflow for coolers which regulates the quantity of water in the tank (bottom of unit) and allows excess water to get channeled directly to a drain which relieves outside. The user controls 106 can include the on/off switch 107 to turn the unit on or off, as needed, and a speed-selection switch 108 to set the speed level for the electric motor 102, which preferably will be a multi-speed electric motor. Preferably, the evaporative media 115 used will be cellulose-based pads with a honeycomb configuration. However, other suitable materials, such as, for example, cardboard, wood wool, and even synthetic materials such as melamine-formadehyde, may suffice.

It is to be understood that the present invention may be used for a variety of cooling situations besides cooling a home or a garage. For example, the evaporative cooling system may be installed in a doghouse, a portable toilet, a greenhouse, or a livestock structure. The evaporative cooling system of the present invention is also suitable for installation in factories, warehouses, and storage facilities. It is to be further understood that although the power source is described as being 120V AC current, that this is only meant as an example. For example, the evaporative cooler of the present invention could be powered with 220V AC current. Furthermore, for some installations, such as a doghouse or a portable toilet, solar panels will preferably be used to power the evaporative cooling system.

The evaporative cooling system 100 of the present invention can be mounted within the wall 140 in many different ways, such as by providing supports 152 below and atop the unit (along with appropriate angle bracing). Such supports 152 can be pieces of 2×4 wood cut to fit and secured by nails or wood screws. However, preferably, a flanged piece that attaches to the unit to cover the sides and attaching to the studs with a set of screws would be used. In this case, the mounting piece would be essentially L-shaped and one side would attach to the housing 106 and the other would be parallel to the wall 140 allowing for securing to the wall studs 150. This would also cover any irregularities in the cut of the drywall by the installer and eliminate the need for any drywall repairs. Although not shown, it is to be understood that many additional features may be included into the evaporative cooling system of the present invention, such as, for example a thermostat or timer. Additionally, a sweep could be employed that would sit below the unit in the wall so that if there was ever a leak then the water would run out into the structure where it could be detected rather than just saturate the wall and cause damage. For example, the sweep could start from behind the unit about an inch from the bottom and continue down the wall but sweep out to the front of the drywall. Preferably, the evaporative cooling system 100 would be sold as a “do it yourself” kit, the kit including the cooling system, mounting elements, and a set of instructions. Alternatively, the evaporative cooling system 100 would be built into the structure during construction.

While this invention has been described in conjunction with the various exemplary embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention. 

1. A cooling system installable within a structure wall, comprising: in a housing, the housing disposed between a pair of studs of the wall, a water reservoir; a pump; a pad; a water distributor; a motor; and a fan.
 2. The cooling system of claim 1, wherein the studs are spaced about sixteen inches on center.
 3. The cooling system of claim 1, wherein the studs are spaced about twenty-four inches on center.
 4. The cooling system of claim 1, wherein the pump brings water from the water reservoir to the water distributor and the water distributor distributes the water to the pad thereby moistening the pad.
 5. The cooling system of claim 4, wherein the fan causes air to flow through the pad moistened by the water, thereby cooling the air by evaporation.
 6. The cooling system of claim 5, wherein the fan causes the cooled air to flow through an opening.
 7. The cooling system of claim 4, wherein at least some of the water flows back to the reservoir for recirculation.
 8. The cooling system of claim 1, wherein the water reservoir is filled with additional water when the water in the reservoir falls below a predetermined level.
 9. The cooling system of claim 8, further including a ball float valve that opens to fill the water reservoir with the additional water when the water in the reservoir falls below the predetermined level.
 10. The cooling system of claim 1, further including a water drain.
 11. The cooling system of claim 1, wherein the housing includes a front cover.
 12. The cooling system of claim 1, wherein the housing protrudes from the wall less than three inches.
 13. The cooling system of claim 1, wherein the wall is a load-bearing wall.
 14. The cooling system of claim 1, wherein the structure is a garage.
 15. A cooling system kit, comprising: the cooling system of claim 1; mounting elements; and a ventilation grill.
 16. The cooling system kit of claim 15, further including instructions.
 17. A cooling system, comprising: in a means for mounting within a structure wall, a means for evaporatively cooling an indoor area.
 18. The cooling system of claim 17, wherein the means for mounting includes placing the means for evaporatively cooling between wall studs spaced about sixteen inches on center.
 19. The cooling system of claim 17, wherein the means for mounting includes placing the means for evaporatively cooling within a structure wall, the structure wall constructed using one of structural insulated panels (SIP) and insulating concrete forms (ICF).
 20. The cooling system of claim 17, wherein the means for enclosing protrudes from the wall less than three inches. 